Contained foam envelope for insulating and sealing large volumes

ABSTRACT

A system for sealing or insulating a large volume is provided. The system includes an envelope having walls defining an interior. The interior is configured to receive a foaming composition. The envelope is initially configured in a retracted configuration. A foaming composition is configured for insertion into the interior of the envelope. The envelope is configured such that the foaming composition expands the envelope such as to fill a large gap.

RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 13/087,413 filed Apr. 15, 2011, entitled “Contained FoamEnvelope for Insulating and Sealing Large Volumes”, which isincorporated by reference herein in its entirety.

BACKGROUND

The present invention relates generally to foams that are used to fillcavities, cracks, and crevices to enhance the sealing and insulatingproperties of buildings and, more particularly, to a foam that iscontained within an enclosed envelope, such as a bag, that can conformto the large volume to be sealed.

Spray foams have found widespread utility in the fields of insulationand structural reinforcement. For example, spray foams are commonly usedto insulate or impart structural strength to items such as automobiles,hot tubs, refrigerators, boats, and building structures. In addition,spray foams are used in applications such as cushioning for furnitureand bedding, padding for underlying carpets, acoustic materials, textilelaminates, and energy absorbing materials. Spray foams are also used asinsulators or sealants for home walls.

Two main classes of spray foams are well characterized: polyurethane(non-aqueous) and latex (aqueous). Typically, polyurethane spray foamsare formed from two separate components, commonly referred to as an “A”side and a “B” side, that react when they come into contact with eachother. The first component, or the “A” side, contains an isocyanate suchas a di- or poly-isocyanate that has a high percent of NCO (nitrogen,carbon and oxygen) functional groups on the molecule. The secondcomponent, or “B” side, contains nucleophilic reagents such as polyolsthat include two or more hydroxyl groups, silicone-based surfactants,blowing agents, catalysts, and/or other auxiliary agents. Thenucleophilic reagents are generally polyols, primary and secondarypolyamines, and/or water. Preferably, mixtures of diols and triols areused to achieve the desired foaming properties. The overall polyolhydroxyl number is designed to achieve a 1:1 ratio of first component tosecond component (A:B).

U.S. Pat. No. 5,444,099 to Abe et al., U.S. Pat. No. 4,945,120 to Koppet al. and U.S. Pat. No. 3,984,360 to Galbreath et al. disclosepolyurethane spray foams which may be capable of being applied at lowtemperatures. The polyurethane foams in each these patents require apolyisocyanate component.

Polyurethane foams can exhibit a number of problems when sprayed intocavities or crevices. First, they contain high levels of isocyanates,such as methylene-diphenyl-di-isocyanate (MDI) monomers. Secondly, theresidual polymeric methylene-diphenyl-di-isocyanate (PMDI) that is notused has an NCO of about 20% and is considered to be a hazardous wastethat can remain in a liquid state in the environment for years.Therefore, specific procedures must be followed to ensure that the PMDIwaste product is properly and safely disposed of in a licensed landfill. Such precautions are both costly and time consuming.

In this regard, attempts have been made to reduce or eliminate thepresence of isocyanate in spray foams and/or reduce or eliminateisocyanate emissions by spray foams into the atmosphere via the use oflatex-based spray foams. Some examples of such attempts are set forthbelow.

U.S. Patent Publication Nos. 2008/0161430; 2008/0161431; 2008/0161433;2008/0161432; 2009/0111902; and 2010/0175810 to Korwin-Edson et al.disclose a room temperature crosslinked latex foam, such as for fillingcavities and crevices. The foam contains an A-side or component thatincludes a functionalized latex and a B-side or component that containsa crosslinking agent, and optionally, a non-reactive resin (e.g., anon-functionalized latex). Either or both the A-side or the B-side maycontain a blowing agent package. Alternatively, the A-side and theB-side may each contain a component such as an acid and a base thattogether form a blowing agent package. A plasticizer, a surfactant, athickener, and/or a co-solvent may optionally be included in either theA- and/or B-side.

U.S. Patent Publication No. 2006/0047010 to O'Leary teaches a spraypolyurethane foam that is formed by reacting an isocyanate prepolymercomposition with an isocyanate reactive composition that is encapsulatedin a long-chain, inert polymer composition. The isocyanate prepolymercomposition contains less than about 1 wt % free isocyanate monomers, ablowing agent, and a surfactant. The isocyanate reactive compositioncontains a polyol or a mixture of polyols that will react with theisocyanate groups and a catalyst. During application, the spray gunheats the polymer matrix, which releases the polyols and catalyst fromthe encapsulating material. The polyols subsequently react with theisocyanate prepolymer to form a polyurethane foam.

Such spray foams are excellent at sealing smaller cracks, joints andcrevices, but generally do not possess sufficient structure to filllarge volumes, such as the gap between floor joists where they intersecta wall dividing conditioned and unconditioned spaces, or the large gapsformed where a chimney passes through a floor joist or the large gapsfound in furnace flue chases, for example. Although these spaces may beinsulated with fibrous insulation, this is generally not sufficient to“seal” the area to prevent air drafts from infiltrating and passing fromunconditioned areas to conditioned areas.

SUMMARY OF THE INVENTION

The above objects as well as other objects not specifically enumeratedare achieved a system for sealing or insulating a large volume. Thesystem includes an envelope having walls defining an interior. Theinterior is configured to receive a foaming composition. The envelope isinitially configured in a retracted configuration. A foaming compositionis configured for insertion into the interior of the envelope. Theenvelope is configured such that the foaming composition expands theenvelope such as to fill a large gap.

According to this invention there is also provided a system for sealingor insulating a pipe or ductwork. The system includes an envelope havingan inner skin and an outer skin configured for wrapping around the pipeor ductwork. The inner skin and the outer skin define an interior. Theinterior is configured to receive a foaming composition. The envelope isinitially configured in a non-rigid structure. A foaming composition isconfigured for insertion into the interior of the envelope. The envelopeis configured such that the foaming composition expands the envelopesuch as to form an insulation structure around the pipe or ductwork.

According to this invention there is also provided a system for sealingor insulating an insulation cavity formed between internal and externalmaterials. The system includes an insulative batt positioned between theinternal and external materials. The insulative batt has a firstcomponent of a foaming composition fused to a surface of the insulativebatt adjacent the external material. An fitment port is configured toextend through the insulative batt and further configured to facilitateinjection of a second component of the foaming composition. The firstcomponent of the foaming composition is configured to react with thesecond component of the foaming composition such as to form a layer offoam composition that seals with the exterior material.

According to this invention there is also provided a system for sealingor insulating an insulation cavity formed between internal and externalmaterials. The system includes an insulative batt positioned between theinternal and external materials. The insulative batt has a surfacepositioned adjacent the external material. A fitment port is configuredto extend through the insulative batt and further configured tofacilitate injection of a foaming composition. The foaming compositionis configured to form a layer of foam composition that seals theinsulative batt with the exterior material.

Various objects and advantages of this invention will become apparent tothose skilled in the art from the following detailed description of thevarious embodiments, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a typical exterior construction, showing theband joist areas of a ground floor and second floor.

FIG. 2 is a side view of typical construction of an overhang orextension of second story living space over exterior or unconditionedgarage space.

FIG. 3A is a front view of an envelope seal according to the invention

FIG. 3B is an enlarged, partly cutaway view of a portion of the envelopeseal of FIG. 3A, and showing one embodiment of an activator for use withthe invention.

FIGS. 4A and 4B are side views of an exterior wall as in FIG. 1, showingfloor and ceiling installations of large volume envelope sealingdevices. FIG. 4A shows the wall before installation and FIG. 4B showsthe wall after installation and activation of the envelope seal.

FIGS. 5A and 5B show alternative methods of installation to a band joistlarge gap area.

FIG. 6A is a front view of an alternate embodiment of the envelope seal;FIG. 6B is cross sectional view of this embodiment taken along line B-Bof FIG. 6A.

FIGS. 7A and 7B show an alternate embodiment of an activation device;before and during activation.

FIG. 8 shows an alternate embodiment of an envelope seal, including amixing matrix inside the envelope.

FIGS. 9A and 9B show variations of the envelope seal that includeperforations for separating portions of the bag to improve the fitaround specific spaces.

FIG. 10 shows an alternate embodiment of an envelope seal that unrollsduring activation.

FIGS. 11A and 11B show an alternate embodiment of an envelope seal foruse with pipe and ductwork.

FIG. 12 shows an alternate embodiment of an envelope seal for use withinsulative batts.

FIG. 13 shows an alternate embodiment of an envelope seal for use withan insulation batt having a facing material.

FIG. 14 shows an alternate embodiment of an envelope seal for use withan insulation batt forming an air space between the insulation batt andan exterior sheathing.

DETAILED DESCRIPTION OF THE INVENTION

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the invention belongs. Although any methods andmaterials similar or equivalent to those described herein can be used inthe practice or testing of the present invention, the preferred methodsand materials are described herein. All references cited herein,including published or corresponding U.S. or foreign patentapplications, issued U.S. or foreign patents, and any other references,are each incorporated by reference in their entireties, including alldata, tables, figures, and text presented in the cited references.

The term “R-value” is the commercial unit used to measure theeffectiveness of thermal insulation and is the reciprocal of its thermalconductance which, for “slab” materials having substantially parallelfaces, is defined as the rate of flow of thermal energy (BTU/hr or Watt)per unit area (square foot=ft² or square meter=m²) per degree oftemperature difference (Fahrenheit or Kelvin) across the thickness ofthe slab material (inches or meters). Inconsistencies in the literaturesometimes confuse the intrinsic thermal properties resistivity, r, (andconductivity, k), with the total material properties resistance, R, (andconductance, C), the difference being that the intrinsic properties aredefined as being per unit thickness, whereas resistance and conductance(often modified by “total”) are dependent on the thickness of thematerial, which may or may not be 1 unit. This confusion, compounded bymultiple measurement systems, produces an array of complex and confusingunits the most common of which are:

English (inch-pound) Metric/SI units Intrinsic resistivity, r(conductivity, k, is reciprocal)$\frac{{hr}*{ft}^{2}*{^\circ}\mspace{11mu}{F.}}{{BTU}*{in}}$$\frac{K*m}{W}$ Total material resistance, R (conductance, C, isreciprocal) $\frac{{hr}*{ft}^{2}*{^\circ}\mspace{11mu}{F.}}{BTU}$$\frac{K*m^{2}}{W}$

For ease of comparisons of materials of differing thicknesses, thebuilding industry sometimes reports thermal resistance (or conductance)per unit thickness (e.g. per inch) effectively converting it to thermalresistivity (conductivity), but retains the traditional symbol, R orR-value.

FIG. 1 illustrates a typical construction of an exterior wall of aresidential unit, although the invention is by no means limited toresidential construction. It shows two examples of typical large gaps10, 11 that can benefit from the invention. A foundation wall 12 isprovided on a footing (not shown). A sill plate 14 is anchored to thetop of the foundation wall 12, typically using an embedded bolt and nutarrangement 16. On top of the sill plate 14 rests all the flooringjoists 18 (one shown) as well as the outer rim or band joist 20, shownin cross section. The joists 18 support the subfloor 22, on which restsbottom plate 24 to support studs 26 for an exterior wall. The exteriorwall may include sheathing 28 and/or other coverings on the exteriorside, and a wall panel such as drywall 30 on the interior of the unit. Alarge gap 10 exists the area between joists 18 and bounded by the uppersurface 14A of sill plate 14, the interior surface 20A of band joist 20and the under surface 22A of the subfloor 22. If the basement isfinished, there may be ceiling material (not shown) fastened to theunderside of joists 18 to provide an additional boundary of the largegap 10.

In similar fashion, a two-story unit has a similar large gap 11, shownin the upper part of FIG. 1. The studs 26 support a top plate 34,typically one or more 2×4s, on which are supported the upper storyflooring joists 38 (one shown) as well as the outer rim or band joist40, shown in cross section. The joists 38 support the subfloor 42, onwhich rests bottom plate 44 to support studs 46 for an upper storyexterior wall. As with the lower story, the exterior wall typicallyincludes sheathing 28 and/or other covering materials on the exteriorside and a wall panel such as drywall 50 on the interior of the unit.The large gap 11 is the area between joists 38 bounded by the undersurface 42A of the subfloor 42, the interior surface 40A of the bandjoist 40, and by the upper surface of top plate 34 and/or ceiling 52. Insome cases, a scrap block 54 is fastened to the upper surface of the topplate 34 to provide an undersurface to which the ceiling 52 can befastened. Thus the top surface of the top plate 34, the top surface ofthe block 54 or the top surface of the ceiling 52 all may potentiallyprovide a lower boundary of the large gap 11.

FIG. 2 illustrates additional types of large gaps 60, 61 that do notabut and are not bounded by a band joist. FIG. 2 depicts a wall 66,formed from stud framing, that divides conditioned space 68 (on the leftside of the wall 66 shown in FIG. 2) and unconditioned space 70 (on theright side of the wall 66). The unconditioned space 70 may be, forexample, a garage, a porch, a crawl-space or simply the exterior overwhich an overhang extends. Wall 66 terminates at its upper end with atop plate 72, upon which floor joists 74 extend to support the subfloor76 of a second story. In a two story building, or even in the atticspace of a one story building, subfloor 76 may support additional walls78, built up from a sole plate 80, that divide conditioned space 82 fromunconditioned space 84. The large gaps 60, 61 are thus the interjoistarea between joists 74 bounded on the top by subfloor 76 and on thebottom by top plate 72 and/or ceiling 52. There is no band joistbounding the large gaps 60, 61 in a third dimension. For a discussion ofsealing air leaks, large gap 60 may be viewed as the area that amountsto an extension of the wall 66 upward into the interjoist space; andlarge gap 61 may be viewed as the area that amounts to an extension ofthe wall 78 downward into the interjoist space.

It is customary in cooler climates to install insulation in theinterjoist spaces between conditioned area 82 and unconditioned area 70.However, typical insulation does little to prevent air leaks and draftsfrom flowing through the interjoist spaces right along the floor joists74. “Sealing” as used herein refers to the prevention or hindering ofthe movement of air such as drafts (i.e. convection) that can movethrough cavities, gaps, and poorly sealed seams whereas “insulating”refers to the prevention or hindering of all forms of heat transfer,including convection, conduction and radiation. Thus, sealing is aspecialized case of insulating. Sealing is also important for noisereduction. The present invention addresses the shortcomings of usingonly insulation in interjoist spaces.

Some typical large volume areas are discussed above and illustrated inFIGS. 1 and 2. However, other large volumes may exist in home orbuilding construction and also may benefit from the invention. Forexample, masonry chimneys often extend through a second floor and/orrafters. There frequently is a large gap between the masonry and theframing lumber. Additionally, chases are sometimes designed and builtinto homes for the passage of wiring, plumbing and exhaust flues. It iscommon to install water heaters and furnaces in the basement and to venttheir exhaust gases through the roof, requiring a chase throughout allfloors. The opening of the chase into the attic (or wherever it changesfrom conditioned to unconditioned space) represents another large gapthat could and should be sealed against drafts and air leaks.

While the above examples of large volumes, cavities or gaps are given,it should be appreciated that these are not the only embodiments oflarge gaps. Large gaps do not have any particular minimum dimensions orshape, and other large gaps may also be envisioned and suitable forsealing using the envelope seals described herein. Generally, however,gaps or cavities are considered “large” if they encompass a volume of atlast 6 cubic inches, more likely at least 12, 24, 48 or 64 cubic inches,and they may be as large as several cubic feet. Although discussed interms of volume and cavities, the depth dimension is more applicablewhen additional R-value or insulation is desired. For sealing alone, avery thin envelope having just two dimensions is suitable, and one mightdescribe it in terms of the area of the gap, but as a practical mattersome insulation effect is often desired as well and the envelope willhave some thickness and volume to provide this. Sealing or insulating orboth are all aspects of the invention.

A large volume or gap is always bounded by a substrate on at least oneside and usually, at least 2, 3 or more substrate/sides. Interjoist gapsare bounded by the two joists as well as one or more of a floor, aceiling, a top plate, a sill plate and optionally by a band joist.Masonry gaps mentioned above are bounded by the masonry and a rafter orother framing structure as substrates. Similarly, a chase is bounded bysubstrate walls that form the chase. These substrates provide surfacesto which envelope seals may be lodged against or attached.

In some embodiments, the large volumes or gaps may not be in residentialor building construction at all, but may occur in automotive, aircraft,marine or other vehicles, or in appliances such as dishwashers, dryers,ovens, refrigerators and the like. Any cavity, void or gap that needs tobe sealed or insulated or both is potentially a large volume gap inaccordance with the invention.

In order to fill and seal the large gaps described above, the inventionprovides in a first “integral” or “self-contained” embodiment anenvelope or bag that already contains a quantity of a foamingcomposition that can be triggered externally to initiate a foamingreaction internally within the envelope to expand it to fill and sealthe large volume. The foaming composition may be thought of as a “unitdose” for the intended envelope or container. Foaming compositions aredescribed below. They are typically, though not necessarily, made in twoparts which, like epoxies, are kept separated until ready for use.Activation triggers are used to combine the two parts to initiate thefoaming reaction. In a different, “bulk” embodiment the bag or envelopedoes not initially contain the foaming composition or an activationdevice, but instead contains a fitment into which a foaming compositioncan be injected. The foaming compositions, if two-part, may be mixed inthe delivery device just prior to injection into the envelope, or theymay be delivered unmixed and mixed within a matrix inside the envelope.Several embodiments of the envelope or bag, including activationtriggers and fitments, are described below in connection with multipleembodiments and with reference to the drawing figures.

Envelopes and Activators

The term “envelope” is synonymous with bag, sac, bladder and similarterms that convey a sealed or sealable container with flexible walls.The envelope may be relatively flat, or it may have side walls or pleatsto give it some depth when expanded. The envelope walls may be elasticand stretch to expand and conform to the volume space it is designed tofill, yet it should be strong enough to absorb the expanding foam in itsinterior without bursting. In some embodiments, the envelope walls maybe sized and shaped to produce a gap filling envelope of specificdimensions and/or shape. At the same time, the foaming composition ismatched in type and quantity to the specific envelope and isself-contained within or adjacent the envelope for an integral package.FIGS. 3 and 4 illustrate such an integral package. In other embodiments,the foaming composition and envelope are not integral and at least someof the foaming composition is added to the envelope through a fitmentport as shown in FIGS. 6 and 8. In still other embodiments, the envelopeis modular and able to be separated into sections along perforations orthe like. FIGS. 9A and 9B illustrate such a modular envelope package.

The envelope may be made of any of a variety of plastic polymers, suchas polyethylene, polyester (e.g. Mylar™), nylon or other polymericmaterial. In other embodiments, the envelope may contain intumescentmaterials to retard flame. In other embodiments, the envelope may bemade of a bio-based material such as polylactic acid.

FIG. 3A illustrates an integral large volume sealing device 110comprising an envelope 116 having a front side 116A and a back side 116B(not seen in FIG. 3A), and an activation trigger 118. The envelope 116has a height, H, a width W, and potentially a depth, D, (not illustratedin this view). The activation trigger 118 is shown near a centerline 120along the width W, dividing the envelope 116 into a right side 116R anda left side 116L. In some embodiments, portions of the front side 116Amay be fused to the back side 116B as shown at areas 122 to create somestructure to the envelope 116, as is described in more detail inconnection with FIG. 6. The envelope 116 may include fastening flangesor straps 124 near its outer edges for fastening the envelope 116 to asubstrate such as a joist. Staples, nails screws or any other fastenermay be driven through the strap 124 to secure the envelope 116 to thesubstrate.

FIG. 3B is an enlarged and partly cut-away view of the activationtrigger 118. In this embodiment, the activation trigger 118 resembles adual barreled syringe, as is sometimes used with epoxies. Hollow syringebarrels 126 extend downward from a mounting plate 128 that is fused orsealed to a wall of the envelope 116, such that the syringe barrels 126are within an interior of the envelope 116 between front side 116A andback side 116B. With common two-part foaming compositions, each syringebarrel 126 contains one part of the foaming composition 130. At thebottom of the syringe barrels 126 are lightweight “release seals” 132that prevent the components of the foaming compositions 130 fromtouching each other until activated. Below the release seals 132—thatis, further toward the interior of the envelope 116—the two syringebarrels 126 merge in a Y-shape junction 134, and then continue into astatic mixer 136 before emptying into the interior of the envelope 116.

External to the envelope 116 at the mounting plate 128, plungers 138extend into each syringe barrel 126, and terminate with a face 140sealed against the inside of the syringe barrel 126 with a suitable sealsuch as an O-ring 142. At the top, the plunger 138 includes a pressurepad 144, or preferably a common pressure pad 144 configured to link theplungers 138 so they may be depressed simultaneously. To preventpremature activation during shipping and storage, a protective sheath146 or cylindrical tube may be inserted between the underside ofpressure pad 144 and the mounting plate 128 so that the plungers 138cannot be inadvertently depressed until the protective sheath 146 isremoved. Other embodiments of activation triggers 118 are describedlater, and would be equally suitable.

In use, the envelope 116 is installed in place in a large gap andoptionally secured there using fastening straps 124. The protectivesheath 146 is removed, and the plungers 138 are depressed into thesyringe barrels 126, increasing the pressure until the release seals 132rupture and the foaming compositions 130 begin to pass through thejunction 134 and mix in the static mixer 136. As the components of thefoaming composition mix, the foaming reaction is initiated and the foambegins to expand the envelope 116 to seal the large gap into which theenvelope 116 was installed.

Static mixers are well known in the industry and require littleadditional description. Many operate by the principles of flow division(repeated stream splitting) and/or radial mixing (rotationalcirculation). Others operate by principles of turbulence or tortuouspath flow. All are designed to blend two or more separate fluid mixturesinto a more homogeneous product. Some static mixers are linear or“in-line” (FIGS. 3B, 5A and 5B) while others are matrix based (FIG. 8).Any static mixer, regardless of its principle of operation, may be usedin the invention provided it affords sufficient mixing of components ofthe foaming composition to initiate a suitable foaming reaction for thesize of the envelope. The static mixer may be part of the envelopesystem itself, as in the embodiment described above, but in otherembodiments described herein the static mixer may be part of a deliverydevice instead.

Several typical installation methods are now described with reference toFIGS. 4, 5, and 6. FIG. 4A illustrates an exterior wall, essentially thesame as FIG. 1, so parts described there are given identical referencenumerals and are not described again here. In FIG. 4A, the large gaps10, 11 are evident in the interjoist areas adjacent the band joists 20,40. Two integral large volume sealing devices 110 are shown between thesubfloor 22 and the ceiling 52. Each sealing device 110 comprises anenvelope 116 and an activation trigger 118. In FIG. 4A, the enveloperight and left sides 116R and 116L have been rolled about the centerlineaxis 120 (see FIG. 3) to form a small diameter cylindrical bundle. Ahole 114A is made in the subfloor and a similar hole 114B is made in theceiling 52 near the wall stud 26 (or drywall 30). The bundled sealingdevice 110 is inserted through the small holes 114A, 114B and into thelarge gaps 10, 11 respectively. When the mounting plates 128 are nearlyin the holes 114A, 114B, the activation triggers 118 are depressed andthe sealing devices 110 are pushed the remaining distance into the holes114A, 114B such that the top pressure pads 144 are within and optionallyfill and seal the holes 114A, 114B.

As the foam expands, the envelope 116 unrolls and expands until thesides of the envelope 116 begin to approach the joists 18, 38 on eitherside as well as the band joists 20, 40 on a third side. The envelope 116expands up and down as well to occupy the large gaps 10, 11. As shown inFIG. 4B, the envelope 116 at the ground floor level is nearly fullyexpanded to contact and seal against the sill plate 14 and the subfloor22, as well as the band joist 20 and flooring joists 18. As notedearlier, the plunger pressure pad 144 may seal the hole 114A or anothersealant/cover may be installed and the flooring or carpeting (not shown)may be replaced over the hole 114A. The envelope 116 at the upper storyfloor is also shown in its nearly fully expanded state, pressing againstthe band joist 40, flooring joists 38, the subfloor 42 and the top plate34 or ceiling 52. Following installation, the hole 114B may easily beconcealed with crown molding 145 or with joint compound or plaster forrefinishing and painting. Although only one interjoist gap isillustrated, it is to be understood that many will occur along any givenwall since joists are generally placed on 16 inch or 24 inch centers. Anintegral large volume sealing device 110 is used to seal and insulateeach of the large gaps 10, 11.

The shape and dimension of the integral large volume sealing device 110may be made specific for the site and installation method. For example,in the installation described above with respect to FIGS. 4A and 4B, theheight H of the envelope 116 may be 8, 10, 12 or more inches tocorrespond to the height dimension of the joists 18, 38. Envelope 116may have a width W of from 14 to about 24 inches depending on theinterjoist spacing and a depth D of from about 2-4 inches up to about8-12 inches. However, these dimension ranges are specific forinstallation through a floor or ceiling as described. Other dimensionsare suitable for other installations.

For example, in FIG. 5A, an alternate installation method is shown. Theintegral large volume sealing device 110 is similar to that describedabove. However, in this method, a hole is made in the band joist 20 fromthe exterior. The integral sealing device 110, with rolled envelope 116,is inserted into the interjoist gap, the activation trigger 118 isdepressed and the foaming begins to expand to fill the envelope 116 andto press against the joists 18, the sill plate 14, the band joist 20 andthe subfloor (not shown in this view). For this installation, the widthW of envelope 116 corresponds to the interjoist dimension as before,but, since it is installed from the side rather than the top or bottom,the depth dimension correlates to the range given above for joistheights (e.g. 8, 10, 12 or more inches) and the height dimension H ofthe envelope 116 corresponds to the range described above for depth.

An external plunger has been described above as one means for triggeringthe foaming reaction. However, an “activation trigger”, as used herein,encompasses any mechanism that can be operated from outside the envelopeto initiate a foaming reaction inside the envelope. Thus activationtriggers may operate one or more of a wide variety of physicalprinciples such as: (1) mechanical motion, such as pulling, pushing, orleverage; (2) pressure differentials, such as air pressure fromcompressed air, manual pressure, pinch rollers, etc; (3) invisiblewaves, such as sound waves (e.g. ultrasound); electromagnetic waves(light, IR, UV, X-ray, microwave, heat, etc); and (4) electricalstimulus, such a voltage potential, shock, etc.

An alternative activation trigger 218 is shown in FIGS. 7A and 7B. Twolayers 219A and 219B of a flexible foil or polymeric plastic are fusedtogether along the edges 220 to create an interior 222. For two-partfoaming compositions, the interior 222 may be divided into twocompartments 222A and 222B by fusing a central pillar 224 as well. Thecompartments 222A and 222B may be tapered as shown by fusions 226 to ajunction area 234 where the layers are joined and sealed to a staticmixer 236. Lightweight release seals 232 keep the compartments 222A,222B closed to the junction area 234 until use. The outlet 238 of thestatic mixer 236 is open to the interior of an envelope seal (not shownin FIG. 7).

Prior to use and fusing the layers 219 a and 219B, the components of afoaming composition are sealed into the compartments 222A, 222B. In use,pressure is applied to the flexible layers 219A, 219B, such as forexample by a pinch roller 240, to force the components of the foamingcomposition to rupture the release seals 232 (FIG. 7B) and to push thefoaming composition into the junction 234 and then to static mixer 236.Eventually, the mixed foaming composition 239 is forced out the outlet238 into the interior of the envelope where it begins expanding theenvelope as described above. The pressure applied to activate theactivation trigger 218 may also come from manual manipulation of theactivation trigger 218 or from a source of compressed air.

The activation trigger 218 will be associated with an integral packageenvelope like 116 with at least the outlet 238 being sealed inside theenvelope interior. Alternatively, the entire static mixer 236 or eventhe entire activation trigger 218 may be within the envelope in someembodiments. It can still be activated from the exterior by applyingsufficient pressure to the trigger. In such cases, it may be desirableto include delayed catalysts in the foaming composition so that thefoaming reaction can be triggered on a bench prior to installation, andthe delay allows sufficient time to install the envelope in the gapbefore the foaming reaction gets underway.

Other Embodiments and Variations

In general, the integral-type large volume sealing device 110 describedabove is particularly well suited for retrofit applications, although itmay also be used in new construction. It is easy to use, even for the‘do-it-yourself’ population, since the prescribed quantity or dose of afoaming composition is self contained within or adjacent the envelopeand can be activated from outside the envelope to initiate the foamingreaction. However, the additional costs associated with the triggeringdevice make this a more expensive choice for the professional contractordoing bulk insulation, particularly in new construction where interjoistgaps and other gaps may be more accessible. For these users andapplications, another package may be preferable, although either typepackage may be used in either application. An alternative embodimentcomprises an envelope having, instead of a foam-filled activationdevice, a port or fitment through which bulk foaming composition may bedelivered to the envelope interior. A delivery device for injecting bulkfoaming composition is dimensioned to attach to the fitment port and topump bulk foaming composition into the envelope. To distinguish thisfrom the “integral package” embodiment, this embodiment is referred toherein as the “fitment” embodiment or “bulk” embodiment.

The bulk embodiment is described below in connection with FIG. 5B, whichillustrates a foundation 12 on which sits a sill plate 14. As before,the sill plate 14 supports band joist 20 and flooring joists 18 which,in turn, support subfloor 22. However, when the building has anaccessible crawlspace or basement below the flooring joists 18 and thejoists are exposed, it is possible to install envelope seal 216 into theinterjoist space from below without making any holes in the subfloor 22or band joist 20. Consequently, envelope seal 216 may comprise anintegral package seal, containing its own foaming composition and anactivation trigger, or it may comprise a bulk embodiment having a portor fitment through which bulk foaming composition can be injected intothe envelope. Fitment port 217 is shown in FIG. 5B. Fitment portsgenerally are described in more detail below.

FIGS. 6A and 6B illustrate another embodiment of an envelope seal 310for sealing a large volume. The envelope seal 310 is similar to theenvelope seal of FIG. 3A, but it lacks an activation trigger. Itcomprises an envelope 316 having a front and back side, a height H2, awidth W2, and optionally a depth D2. It may comprise flanges or straps324 for securing the envelope 316 to a substrate, such as flooringjoists 38. As with the embodiment of FIG. 3A, the envelope 316 maycomprise areas 322 where the front and back walls or panels of theenvelope are fused together. Such fused areas help give shape andstrength to the expanded envelope as seen in FIG. 6B. As before, whenthe envelope 316 is expanded, it seals against the joists 38, the topplate 34 or ceiling 52, and the subfloor 42. Notably, no band joist isshown, as this Figure illustrates the “wall extension” type ofinstallation to fill large gaps 61, 62 as described above in connectionwith FIG. 2. It should be appreciated, however, that this embodiment isnot limited to installation for this type of gap and is equally wellsuited to band joist or other large gaps.

Instead of an activation trigger, this embodiment is the “bulk” or“fitment” type and has a fitment port 317 on an exterior face of theenvelope 316 which communicates to the interior. Fitment ports may vary,but a simple design consists of a hollow cylindrical piece of plastic orpolymer with a flange that allows it to seal against the envelope 316(see also FIG. 8). The main constraint is that fitment ports can, withor without the use of adapter sleeves, tightly interact and seal with anozzle or barrel of a bulk foaming composition delivery device. Forexample, a nozzle of a delivery gun may be cylindrical, and the fitmentis a hollow cylinder dimensioned to receive the nozzle and tightly sealagainst it so that bulk foaming composition is delivered to the interiorof envelope 316 without leaking or spilling. A slight tapering of thefitment wall or the device nozzle may enhance the seal. Fitment port 317may contain a valve (not shown) for allowing entry but preventing egressof bulk foaming composition; and it may contain deflectors or baffles(not shown) for directing the injected foam to various areas of theinterior.

When expanded, the envelope 316 includes tubular ribs 315 separated bythe fused areas 322 as best seen in FIG. 6B. This arrangement providesadditional strength and, by limiting depth D2, urges the expandingenvelope outward against its substrates (e.g. subfloor 42, top plate 34and flooring joists 38) for a better seal instead of allowing the foamto expand the envelope 316 laterally into the interjoist spaces.Additionally, in any of the embodiments described herein, the envelope316 may include leak pores or perforations (described below inconnection with FIG. 9B) around the perimeter of the envelope 316. Suchleak pores allow small amounts of foam to seep out of the interior toensure a good seal against the substrate all around the envelope 316.

In the simple fitment port 317 described above, the foamingcomposition—if a two-part composition—must be mixed prior to enteringthe fitment port 317. This is also true of traditional two-part sprayfoams so existing delivery devices are generally capable of drawing upcomponents from two sources, pumping them to a location, and mixing themin a delivery gun just before they are applied to a site. Such deliveryguns are known in the art and are suitable for use to inject foamingcompositions into envelopes with simple fitment ports like 317. Thenozzle of the delivery device is generally cylindrical and can beinserted into the cylindrical fitment port. Adapters may be used ifneeded to ensure tight fits with no leakage of foaming composition.Simple friction fits are generally sufficient, although more complexbayonet mounts or screw mounts are possible and within the purview ofthe invention.

FIG. 8 shows in cross section an alternate fitment port 417 that doesnot require the components of the foaming composition to be mixed priorto entry into the fitment port. Thus it keeps delivery gun nozzles freeof mixed foaming composition, rendering them easier to clean after use.Fitment port 417 comprises a cylindrical flanged plastic part 410 fusedto one wall (416A) of an envelope 416 of construction similar to thatpreviously described. Flanged part 410 consists of an annular or tubularwall 412 hollow throughout, molded to a flange 414 to provide a base forfusion to the front wall 416A of envelope 416. Envelope front wall 416Aincludes an opening or hole 420 in registry with the hollow core of theannular wall 412. On the interior side of envelope front wall 416A, afibrous matrix 422 is fixed in the area where the flanged part 410 opensthrough hole 420 into the interior 413 of the envelope 416.

The fibrous matrix 422 may be made of polymer or inorganic fibers andmay be bonded fibers or woven or non-woven fibers. It will be sizedappropriately for the envelope size and quantity of foaming composition,to provide a mixing effect for foaming composition components that areinjected through the fitment port into the matrix. Baffles or diverters(not shown) may be employed to direct foaming composition through asufficient tortuous path of the fibrous matrix 422 to effect thenecessary mixing. In particular, an impervious barrier layer 424 ofpolyethylene or the like may be applied to the face of the fibrousmatrix that is furthest from the envelope front wall 416A. This helpscontrol the flow path of the foaming composition to direct itperpendicular to the flow through the fitment wall 412, so that it flowsthrough more of the fibrous matrix 422 and improves mixing.Additionally, the fibrous matrix 422 provides some separation of theback wall 416B from the front wall 416A.

FIG. 9A illustrates a further embodiment of an envelope seal 510produced in bulk. Individual envelopes 516A and 516B are shown attachedtogether at perforation tear line 520, which may also include a fusedseam border along the perforation tear line 520. In likewise manner,envelope 516B is attached to envelope 516C, etc as roll 518 to the leftin FIG. 9A suggests. Each envelope on the roll 518 has a height H3 and awidth W3, and optionally a depth D3, not shown. The width W3 correspondsto the spacing between perforation lines 520. Depending on theembodiment, the front and back side may be fused in areas 522 to createribs 515 as described in connection with FIG. 6. Lo-rise fitment ports517 may be added for the purpose of injecting a foaming composition orcomponent(s) thereof. One or two fitment ports 517 are shown perenvelope, for example. They may be similar to other fitment portsdescribed, except that, for producing a rolled product, the depth of theport should be minimized to reduce bulk. Thus, low-rise fitments arepreferred.

This roll product is easily manufactured in long webs of intermittentlyfused layers, and rolled for shipping and storage. In use, one simplyunrolls the web, separates an envelope along a perforation line, securesit to the desired substrate and connects a source of foaming compositionto the fitment through a delivery device as described above. As withprior embodiments, the envelope 516 may be made in standard heights andwidth to fit conventional gap areas. Alternatively, by spacing theperforation lines 520 closer together (more frequently), the roll may beproduced with fractional widths W3, such that multiple envelopes areused to fill a large volume. This modular approach offers moreflexibility in filling gaps of varying sizes. In another variation, theroll may omit the perforation lines 520 and the user simple cuts theenvelope to length along any fused area 522. Since the fused seam is nolonger present, this variation produces an envelope that is open at thecut end along the top and bottom. This area may be fused manually, or itmay be left open so that foam may extrude from this opening to furtherseal corner areas of a large gap and to further secure the envelope inposition attached to the substrate such as a joist.

An alternative modular embodiment is illustrated in FIG. 9B. In thisembodiment the envelope seal 615 is designed to be modular so as to fitirregular spaces better. One example of such an irregular space is wherea duct or pipe extends through a band joist, as is the case, forexample, with a dryer vent or a high efficiency furnace air intake andexhaust. Each envelope seal 615 is made up of a plurality of smallersegments 616 that are attached together much like a quilt. In reality,during manufacturing, a web of envelopes is manufactured and dividedinto segments 616 by fusing a seam 618 in a machine direction, and aseam 619 in a cross-machine direction, although these machine directionsare arbitrary to the final orientation of the envelope seal 615 shown.Within the width of each fused seam 618, 619 a perforation line 620 isinserted, so that a portion of the segments 616 can be separated fromthe others in order to fit an irregular space.

In the specific embodiment illustrated in FIG. 9B, six segments 616A-Fare removed from the bulk web in a 2×3 matrix in order to fill a volumesuch as a joist gap. However, to fit the envelope seal 615 into anirregular volume in which a pipe 640 extends, the upper center segment616B (shown in phantom) is separated from the other segments 616A and616C-F to make room for pipe 640. “Separated” in this contextencompasses complete removal of the unused segment as well as partialremoval by making tears or cuts along perforations or not to make roomfor the obstruction that makes the space irregular. For example, segment616B might be separated along the perforations between 616B-616C andbetween 616A-616B, and hinged downward along the perforation seam 618between segments 616B and 616E. Alternatively, a cut may be made downthe center of absent segment 616B, and the 616B-616E perforation may beseparated so that each half opens like two doors folding behind segments616A and 616B. Finally, segment 616B may be separated from all threeremaining sides and removed, as is the case represented in FIG. 9B.

Envelope segments 616A-F all include a fitment port 617 as was describedpreviously for injecting a foaming composition to the interior ofenvelope. Since the volume of each segment 616A-F is relatively small,it may be useful to provide a keying means to inform the delivery devicehow much volume to inject. RFID tags 630 can be used to convey thisinformation to the delivery device.

In some embodiments, it may be desirable to provide strategic “leak”pores in the envelope. In FIG. 9B these leak pores take the form of arcs632 that represent small holes punctured in the envelope wall. As withthe cut end of the envelope 516 described above, leak pores like thisallow the foam to extrude in a controlled fashion to further seal thegap and secure the envelope in place. In FIG. 9B, foam 635 is shownextruding from the right side of segment 616A and from the top ofsegment 616E to further seal the space around the pipe 640. Once thefoaming composition is injected and begins to expand, it would alsoextrude from all of the other pores or arcs 632 as represented bycertain arrows 637, but not shown as foam. The amount and type of foamused is desirably chosen so that these strategic leak pores further sealthe gap area, further secure the envelope in place and potentially evenadd insulation value and strength to the envelope. As other segments 616are filled (E.g. 616C and 616F) they too would ooze or extrude foam viathe arcs 632 to complete the seal of the gap around the pipe 640, tofurther secure the envelope in place, and to further strengthen andinsulate the seams 618, 619.

The choice of size of the segments is simply one of tradeoffs. Thesmaller the size of each segment, the greater the flexibility in shapingthe envelope to fit an irregular volume. The concept is much that sameas resolution of a monitor—the more pixels, the higher the resolution ofthe image. The tradeoff is that there are more ports to fill with evensmaller quantities, thus contributing to labor costs. Balancing thistradeoff is within the purview of those skilled in the art to designreasonable flexibility with minimal labor time and expense. For typicalinterjoist gaps, the number of segments may range from 1 to about 24,more likely from about 1 to about 12 segments. However, the number isnot critical and will certainly vary for other types of large volumes.

Foaming Compositions

The foams that may be used within the envelope may be of any of theknown types of foaming compositions, including both open and closed cellfoams. Generally speaking, foaming compositions include two reactivefilm-forming ingredients; a structure, scaffold or skeleton former; anda blowing agent. Other additives may be present of course as is taughtin connection with known foaming compositions. The foams may beone-part, but reactive components must be kept separated until ready toinitiate the foaming reaction. An easy way to keep the reactivecomponents separated until desired is to package them in separatecompartments or containers, which gives rise to description in theliterature of “two-part” foaming compositions. Any of the one-part ortwo-part foams described in any of the following references, each ofwhich is incorporated in its entirety by reference, can be used with thepresent invention.

-   -   U.S. Pat. No. 5,444,099 to Abe et al., U.S. Pat. No. 4,945,120        to Kopp et al. and U.S. Pat. No. 3,984,360 to Galbreath et al.        disclose polyurethane foams.    -   U.S. Patent Publication Nos. 2008/0161430; 2008/0161431;        2008/0161433; 2008/0161432; 2009/0111902; and 2010/0175810 to        Korwin-Edson et al. disclose latex foams.    -   U.S. Patent Publication No. 2006/0047010 to O'Leary discloses a        polyisocyanate prepolymer foaming composition.    -   U.S. patent application Ser. Nos. 12/875,640, filed Sep. 3, 2010        and 61/421,680 filed Dec. 10, 2010 to O'Leary disclose        non-aqueous based foaming compositions that will nevertheless        foam at room temperatures.

The availability and low cost of isocyanate/polyol reagents that makelow density polyurethane foams are well suited for use with the presentinvention. They are well tested and understood in the industry and makelow density open cell foams in the 0.25 to 3 pound per cubic foot (pcf)range. While these foams have been avoided for spray applications, dueto health concerns related to inhaling dangerous vapors, these dangersare removed or minimized in the present invention for two principlereasons. First, the foam is not sprayed or atomized so that it is moredifficult to inhale. Even in the embodiment where a delivery gun ordevice is used, the foam is injected directly into the interior of theenvelope and does not generally escape to the atmosphere. Second, thefoam is largely self-contained within the envelope. Although someembodiments have strategic leak pores that allow some foam to escape,these are placed at the perimeters of the envelopes so that the foam hastime to polymerize and set up before leaking to the exterior. In thisway no toxic monomeric NCO's are likely to escape.

The foaming composition may contain other optional ingredients, ineither or both of an A-side and B-side when two-part foams are used.Such optional ingredients may include catalysts, a nucleating agent,coagulation agents, foam promoters, opacifiers, accelerators, foamstabilizers, dyes (e.g., diazo or benzimidazolone family of organicdyes), color indicators, gelling agents, flame retardants, intumescents,biocides, fungicides, algaecides, fillers (aluminum tri-hydroxide(ATH)), and/or blowing agents. It is to be appreciated that a materialwill often serve more than one of the aforementioned functions, as maybe evident to one skilled in the art. The additives are desirably chosenand used in a way such that the additives do not interfere with themixing of the ingredients, the cure of the reactive mixture, the foamingof the composition, or the final properties of the foam. Other optionaladditives can be between 0 and 10% of the final formulation.

Some specific flame retardants include: Triethyl Phosphate TEP,Tributoxyl Ethyl Phosphate (TBEP), Tri-isobutyl Phosphate (TIBP), Tris(2-Chloroisopropyl)Phosphate (TCPP),Tris(1,3-dichloro-2-propyl)Phosphate (TDCP), Triphenyl Phosphate (TPP),Tricresyl Phosphate (TCP), Triphenyl Phosphite, Triphenyl Phosphine,Tris (2-chloroethyl)Phosphate (TCEP), 1-Phenyl-3-Methyl-5-Pyrazolone(PMP), Acetoacetanilide (AAA, and Phosphate Flame Retardants BDP andRDP.

As mentioned earlier, for some embodiments it may be desirable to delaythe onset of the foaming reaction once the trigger is activated. Sometypes of activation triggers may be used after the envelope isinstalled, while other types may be used on a bench or surface justprior to installation. In the latter case, delaying the onset of foamingto allow time to install the envelope may be desired. Certain modifiedcatalysts can do this. Notably, to create a delayed action, formic acidcan be added to either a gel catalyst such as TEDA—Triethylene amine orDBTDL—Dibutyltindilaurate; or to a blowing catalyst such asBDMAEE—bis(2-dimethylaminoethyl ether) or DMDEE—2,2′ Dimorpholinodietylether.

In exemplary embodiments, the foams of the present invention, as well asthe components thereof, meet certain performance properties, or Fitnessfor Use (“FFU”) criteria, both chemical and physical. In particular,desired criteria or FFUs that the inventive foam should meet are setforth in the table below:

Chemical Criteria Physical Criteria The foam should adhere to variousThe foam weight should be between materials such as wood, metal, about0.2 and about 4.0 pounds per concrete and plastic cubic foot Thechemical constituents should The foam should be fluid enough to be safe.Even though isocyantates be sprayed either at room temperature may beused, the dangerous or by heating (viscosity of <10,000 monomeric NCOsare not cP at a high shear rate) introduced or atomized into the air Thefoam should not sag or fall in the where they can be inhaled; even ifcavity they extrude from the leak pores, The foam should fill in cracksand they are substantially polymerized crevices or be used to coat thecavity by then. with an air barrier The foam may be chemically Ideally,the cell structure of the foam foamed through the use of a (closed vs.open) should be open cell blowing agent or it may be structure toprovide appropriate mechanically foamed with a gas material densityproperties and The installer of the foam should be avoid volatileblowing agents able to work with the material The foam should have athermal without any specialized personal resistance (R-value) of atleast 3.0° protective equipment (“PPE”), such Fft²h/BTU per inch as abreathing apparatus, although The foam should be non-sagging andchemical goggles, dust mask, and non-dripping (i.e., fire retardant)gloves are acceptable during a fire The foam should not lend itself toThe foam should not corrode metal molding or fungus growth (ASTM objectssuch as screws, nails, electrical C1338) boxes, and the like The foamshould not contain a Air infiltration should be negligible food sourcefor insects or rodents (ASTM E283-04) (spec 0.4 cfm/sq ft) There shouldbe a minimum shelf Water vapor infiltration should be life of theun-reacted constituents greater than 1 perm or of 9 months. 5.72 × 10⁻⁸g/Pa-s-m² The foam should have low or no odor.Methods and Process

The final foamed product becomes cured to the touch within minutes afterapplication, and hardens within about 1 to 6 minutes. In foams intendedfor use as insulating materials, the resulting resistance to heattransfer, or R-value, is desirably from about 3.5 to about 8 per inch.In certain uses, the foamed product has an integral skin that restrictsthe passage of air but permits the passage of water vapor.

Another advantage of the foams of the present invention is the safeinstallation of the foam into cavities. Because the foams do not releaseany harmful vapors into the air when applied or sprayed, the inventivefoams reduce the threat of harm to individuals working with or locatednear the foam. In addition, the application of the foams is moreamenable to the installer as he/she will not need to wear a specialbreathing apparatus during installation.

Another advantage of the inventive foams is that it can be used in therenovation market, as well as in houses that are occupied by personsand/or animals (e.g. renovation market). Existing spray polyurethanefoams cannot be used in these applications because of the generation ofhigh amounts of free isocyanate monomers that could adversely affect theoccupants of the dwelling. As discussed above, exposure of isocyanatemonomers may cause irritation to the nose, throat, and lungs, difficultyin breathing, skin irritation and/or blistering, and a sensitization ofthe airways.

Referring now to FIG. 10, another embodiment of an envelope seal isshown generally at 715. The envelope seal 715 includes an envelope 716that, in a retracted position, is in the form of a roll. The rolledenvelope 716 is positioned between framing members 718 and fastened toan underside of a subfloor 722. While the illustrated embodiment shows aretracted envelope 716 in the form of a roll, it is within thecontemplation of the invention that the retracted envelope 716 can takeother forms, such as the non-limiting examples of a folded envelope or abellows-style envelope.

Referring again to FIG. 10, the retracted (rolled) envelope 716 caninclude straps (not shown) or other desired structures, mechanisms ordevices sufficient to facilitate fastening to the underside of thesubfloor 722.

The envelope 716 includes a fitment port 717. The fitment port 717 isconfigured to facilitate injection of bulk foaming composition into theinterior of the retracted envelope 716. In the embodiment illustrated inFIG. 10, the fitment port 717 is the same as, or similar to, the fitmentport 217 illustrated in FIG. 5B and described above. In otherembodiments, the fitment port 717 can be the same as, or similar to, thefitment port 417 illustrated in FIG. 8 and described above. In stillother embodiments, the fitment port 717 can be different from thefitment ports 217 or 417. In still other embodiments, the envelope 716can be of the “integral” type, as discussed above, thereby containing aquantity of a foaming composition that can be triggered internally orexternally to initiate a foaming reaction internally within the envelope716 to expand it to fill and seal a large gap 710.

In operation, the envelope 716, in the retracted and rolledconfiguration, is fastened to the underside of the subfloor 722. Foam isinserted into the interior of the rolled envelope 716 through thefitment port 717. The insertion of the foam urges the retracted envelope716 to unroll in a generally downward direction as indicated by arrows745. As the envelope 716 unrolls, the envelope 716 is acted upon by theexpanding foam within the envelope 716 and also by the force of gravity,to fill the large gap 710 between the framing members 718 and theundersurface of the subfloor 722. In an expanded position, the envelope716 is substantially within the same vertical plane as the framingmembers 718.

Optionally, the envelope 716 can contain strategic “leak” pores 732. Theleak pores 732 are configured to allow the foam 735 to extrude in acontrolled fashion to further seal the large gap 710 and secure theexpanded envelope 716 in place between the framing members 718 and theundersurface of the subfloor 722. In the illustrated embodiment, theleak pores 732 are the same as, or similar to, the leak pores 632illustrated in FIG. 9B and discussed above. Alternatively the leak pores732 can be different from the leak pores 632.

Advantageously, the envelope seal 715 illustrated in FIG. 10 can be usedwith other types of framing members 718, including the non-limitingexample structural (I-beam) joists.

As discussed above, spray foams have found widespread utility in thefields of insulation and structural reinforcement. For example, sprayfoams are commonly used to insulate or impart structural strength toitems such as automobiles, hot tubs, refrigerators, boats, and buildingstructures. In addition, spray foams are used in applications such ascushioning for furniture and bedding, padding for underlying carpets,acoustic materials, textile laminates, and energy absorbing materials.Spray foams are also used as insulators or sealants for home walls.

Referring now to FIGS. 11A and 11B, another embodiment of an envelopeseal is shown generally at 815. In this embodiment, the envelope seal815 is used to insulate pipe 853 or duct used in residential orindustrial applications. Generally, the envelope 816 is configured to bewrapped around the pipe 853 and filled with foam.

Referring first to FIG. 11A, the envelope seal 815 includes an envelope816 having an inner skin 850 and outer skin 852. In the illustratedembodiment, the inner and outer skins, 850, 852 are formed from the samematerial as used to form the envelope 116 as shown in FIG. 4B anddiscussed above. Alternatively, the inner and outer skins, 850, 852 canbe formed from other materials. The inner skin 850 and outer skin 852can include straps (not shown) or other structures, mechanisms ordevices sufficient to facilitate fastening of the inner and outer skins,850, 852, as the envelope is wrapped around the pipe 853. An interiorspace 854 extends between the inner skin 850 and the outer skin 852.

The envelope 816 includes a fitment port 817. The fitment port 817 isconfigured to facilitate injection of bulk foaming composition into theinterior space 854 of the wrapped envelope 816. The fitment port 817 cantake any of the forms discussed above.

In operation, the envelope 816 is wrapped around the pipe 853 such thatlongitudinal edges of the inner skin 850 are fastened together andlongitudinal edges of the outer skin 852 are fastened together. In thewrapped position, the inner and outer skins, 850, 852 are configured tobe “non-rigid” structures. The term “non-rigid”, as used herein, isdefined to mean that the inner and outer skins, 850, 852 are flexibleand prior to the application of the foam and do not assume specificshapes. As shown in FIG. 11B, foam is inserted through the fitment port817 and into the interior space 854 between the inner and outer skins850, 852. The insertion of the foam provides pressure against the innerand outer skins, 850, 852 such as to form an insulation structure 860.The insulation structure 860 includes the inner and outer skins 850, 852connected by a layer of foam 862 therebetween.

Referring again to FIG. 11B, optionally the inner and outer skins, 850,852 can be connected to each other by a plurality of members 864positioned within the interior space 854. The members 864 have a lengthL configured to define a thickness of the resulting layer of foam 862.By defining the thickness of the resulting layer of foam 862, theresulting insulative value R can be defined. In the illustratedembodiment, each of the members 864 has the same length L, therebyallowing the inner and outer skins 850, 852 to be concentric withrespect to each other. In other embodiments, the members 864 can havedifferent lengths, thereby allowing a non-concentric arrangement betweenthe inner and outer skins 850, 852. While the embodiment illustrated inFIG. 11B shows the members 864 as having a radial orientation, it iswithin the contemplation of this invention that the members 864 can haveother orientations or include other structures sufficient to connect theinner and outer skins, 850, 852 to each other.

Referring again to FIG. 11A, optionally, the envelope 816 can containstrategic “leak” pores 832. The leak pores 832 are configured to allowfoam 835 to extrude from the inner skin 850 in a controlled fashion tofurther seal a gap between the inner skin 850 and the pipe 853, as shownin FIG. 11B. Further, the leak pores 832 are configured to position theresulting insulation structure 860 such as to be radially concentricabout pipe 853. In the illustrated embodiment, the leak pores 832 arethe same as, or similar to, the leak pores 632 illustrated in FIG. 9Band discussed above. Alternatively the leak pores 832 can be differentfrom the leak pores 632.

While the resulting insulation structure 860 illustrated in FIG. 11B hasa generally circular cross-sectional shape, it should be appreciatedthat in other embodiments, the resulting insulation structure can beconfigured to have other cross-sectional shapes, such as thenon-limiting example of a square cross-sectional shape. Advantageously,the envelope seal 815 illustrated in FIGS. 11A and 11B can have anydesired length.

While the embodiment illustrated in FIGS. 11A and 11B has been describedabove as incorporating a non-rigid inner and outer skin, 850 and 852, itis within the contemplation of this invention that the inner and/orouter skins could be formed from materials or combinations of materialsresulting in rigid structures. The term “rigid”, as used herein, isdefined to mean that the inner and outer skins are inflexible prior tothe application of the foam and can have specific shapes. As onenon-limiting example of the inner and outer skins having a rigidstructure, the inner and/or outer skins could have the form of aclam-shell like structure, wherein the structure is hinged along onelongitudinal edge.

As discussed above, the foams that may be used within an envelope may beof any of the known types of foaming compositions, including both openand closed cell foams. In other embodiments incorporating any of theenvelopes 116, 216, 316, 416, 516, 616, 716 and 816 discussed above, thefoaming composition can include ceramic foam. The term “ceramic foam”,as used herein, is defined to include any foam component or materialutilizing a ceramic material, such as the non-limiting example ofaluminum oxide. In certain embodiments, the ceramic foam can be usedwithin the envelopes 116, 216, 316, 416, 516, 616, 716 and 816 in any ofthe manners discussed above. Alternatively, the ceramic foam can be usedwithin the 116, 216, 316, 416, 516, 616, 716 and 816 using other methodsand techniques.

As also discussed above, when filled with the foam, the envelopes 116,216, 316, 416, 516, 616, 716 and 816 stretch to expand and conform tothe volume space it is designed to fill. In another embodiment, the foamconfigured to fill the envelopes 116, 216, 316, 416, 516, 616, 716 and816 can include an additive or additives configured to dissolve theenvelope in a controlled manner, such as to allow the expanding foam toform an intimate seal with the structure surrounding the volume space.The expansion of the foam within the controlled manner allows the foamto generally retain the shape of the envelope until the foam seals withthe surrounding structure. Any desired additive can be used.

While the embodiments discussed above have been illustrated anddescribed as foaming compositions contained in envelopes or bags, itshould be appreciated that in other embodiments, the foamingcompositions can be configured with other structures, mechanisms anddevices. Referring now to FIG. 12, another sealing embodiment is showngenerally at 915. Generally, this embodiment involves the forming of afoam-based seal between the outboard side of a fibrous batt and theinboard side of an exterior panel.

Referring again to FIG. 12, a portion of a building sidewall 972 isillustrated. The sidewall 972 is configured to define interior spacewithin the building and to support additional structural components. Thesidewall 972 can be formed from various structural framing members, suchas the non-limiting examples of bottom plates (not shown), top plates(not shown) and studs (not shown) extending therebetween. The bottomplates, top plates and studs can be configured to provide surfaces towhich additional framing members or wall panels can be attached. Incertain embodiment, the various structural framing members are made ofwood. In other embodiments, the various structural framing members canbe made of other desired materials, including the non-limiting exampleof steel. The various structural framing members can have any desireddimensions.

Referring again to FIG. 12, the exterior of the sidewall 972 is coveredby an exterior sheathing 974 attached to the various structural framingmembers. The exterior sheathing 974 is configured to provide rigidity tothe sidewall 972 and also configured to provide a surface for anexterior wall covering (not shown). In the illustrated embodiment, theexterior sheathing 974 is made of oriented strand board (OSB). In otherembodiments, the exterior sheathing 974 can be made of other materials,such as for example plywood, waferboard, rigid foam or fiberboard,sufficient to provide rigidity to the sidewall 972 and to provide asurface for an exterior wall covering. As shown in FIG. 12, the exteriorsheathing 974 has an interior surface 975.

The interior of the sidewall can be covered by construction material977. The construction material 977 can be any desired material orcombination of materials, including the non-limiting examples of drywalland paneling. The construction materials 977 have an exterior surface978.

Insulation cavities 980 can be formed in the spaces between the variousstructural framing members, the interior surface 975 of the exteriorsheathing 974 and the exterior surface 978 of the construction material977. The term “insulation cavity” as used herein, is defined to mean anyspace within the building within which insulation is desired, includingthe non-limiting examples of a building attic or sidewalls. In certainembodiments, the insulation cavities 980 can extend from the bottomplate to the top plate. In other embodiments, the insulation cavities980 can extend from the bottom plate or the top plate to a buildingfixture, such as for example a window (not shown). While the insulationcavity 980 illustrated in FIG. 12 is shown as being located in thesidewall 972 of a building, it should be appreciated that otherinsulation cavities can occur in other locations of the building, suchas the non-limiting example of an attic space. The insulation cavities980 can have any size, shape or configuration and can be formed betweenany building components or members.

Referring again to FIG. 12, an insulative batt 982 can be positionedwithin the insulation cavity 980. The insulation batt 982 is typicallyfibrous glass having a density within the range of from about 0.3 toabout 1.5 pounds per cubic foot (pcf), although other densities can beused. Also, other fibers, such as mineral fibers of rock, slag orbasalt, can be used as well as organic fibers, such as the polymerfibers polypropylene, polyester and polysulfide. In certain embodiments,the fibers can be, but not necessarily, bonded together with a bindermaterial, such as a urea phenol-formaldehyde commonly used withfiberglass insulation, to provide stiffness to the insulative batt 982.It will be appreciated that any binder material suitable for bonding thefibers together may be used. The insulative batt 982 can be installed inthe insulation cavity 980 in any desired manner.

The insulative batt 982 includes an interior surface 984, positioned tobe adjacent the exterior side 978 of the construction material 977, andan exterior surface 985, positioned to be adjacent the interior surface975 of the exterior sheathing 974.

In this embodiment, the exterior surface 985 of the insulative batt 982has been fused with a first component 987 of a two part foamingcomposition, as described above. The first component 987 can either bethe “A” side of the foaming composition or the “B” side of the foamingcomposition. In certain embodiments, the first component 987 can befused to the exterior surface 985 of the insulative batt 982 by anadhesive. Alternatively, the first component 987 can be fused to theexterior surface 985 of the insulative batt 982 by other methods,including the non-limiting examples of heating or sonic welding.

The insulative batt 982 includes a fitment port 917 that extends fromthe interior surface 984 of the insulative batt 982 to the exteriorsurface 985 of the insulative batt 982. The fitment port 917 isconfigured to facilitate injection of a second component of the foamingcomposition to the exterior surface 985 of the insulative batt 982. Thefitment port 917 can take any of the forms discussed above. While theembodiment shown in FIG. 12 illustrates an insulative batt 982 having asingle fitment port 917, it should be appreciated that in otherembodiments, the insulative batt 982 can have more than one fitment port917.

In operation, the sidewall 972 is constructed using the variousstructural framing members. The exterior sheathing 974 is fastened tostructural framing members. Insulative batts 982 are positioned withinthe insulation cavities 980 formed by the various structural framingmembers and the exterior sheathing 974. The exterior surface 985 of theinsulative batts 982 includes a first component 987 of the foamingcomposition. The second component of the foaming composition is piped,via the fitment port 917, through the body of the insulative batt 982,to the exterior surface 985 of the insulative batt 982, such as to comeinto contact with, and react with the first component 987, therebyforming a layer of foam composition 990. The layer of foam composition990 extends the length of the insulative batt 982 from the exteriorsurface 985 of the insulation batt 982 to the interior surface 975 ofthe exterior sheathing, wherein the foam composition 990 forms anintimate seal with the exterior sheathing 974. The layer of foamcomposition 990 has a thickness TF. In the illustrated embodiment, thethickness of the layer of foam composition is in a range of from about0.1 inches to about 0.3 inches. In other embodiments, the layer of foamcomposition can be less than about 0.1 inches or more than about 0.3inches. After the foam composition 990 is formed, the constructionmaterial 977 can be fastened to the various structural framing materialsas discussed above.

While the embodiment illustrated in FIG. 12 has been described above asforming foam composition by piping a second component through thefitment port 917 such as to react with the first component 987 fused tothe exterior surface 985 of the insulative batt 982, it should beappreciated that in other embodiments, a pre-mixed foam composition canbe piped through the fitment port 917. The pre-mixed foam compositioncan extend from the exterior surface 985 of the insulation batt 982 tothe interior surface 975 of the exterior sheathing, wherein the foamcomposition forms an intimate seal with the exterior sheathing 974.

While the embodiment illustrated in FIG. 12 was described above asforming foam composition along the length of the insulative batt 982, inother embodiments only the side surfaces (not shown) of the insulativebatt 982 are fused with the first component 987 of the foam composition.In these embodiments, piping a second component through the fitment port917 allows a reaction with the first component 987 such as to form anintimate seal between the side surfaces of the insulation batt 982 andthe interior surface (not shown) of the various structural framingmembers. The layer of foam composition formed along the side surfaces ofthe insulative batts 982 can have any desired thickness.

Another sealing embodiment utilizing a foam composition with aninsulative batt is illustrated in FIG. 13 generally at 1015. Generally,this embodiment involves the use of a facing material on the insulativebatt. The facing materials acts as a barrier to prevent the foamcomposition from penetrating the fibers of the insulative batt as thefoam composition forms a seal between the outboard side of a fibrousbatt and the inboard side of an exterior panel.

Referring again to FIG. 13, a portion of a building sidewall 1072 isillustrated. The sidewall 1072 includes various structural framingmembers (not shown), an exterior sheathing 1074 attached to the variousstructural framing members, construction material 1077, insulationcavity 1080 and an insulative batt 1082 positioned within the insulationcavity 1080. In the illustrated embodiment, the various structuralframing members, exterior sheathing 1074, construction material 1077,insulation cavity 1080 and insulative batt 1082 are the same as, orsimilar to, the various structural framing members, exterior sheathing974, construction material 977, insulation cavity 980 and insulativebatt 982 illustrated in FIG. 12 and described above. In otherembodiments, the various structural framing members, exterior sheathing1074, construction material 1077, insulation cavity 1080 and insulativebatt 1082 can be different from the various structural framing members,exterior sheathing 974, construction material 977, insulation cavity 980and insulative batt 982 illustrated in FIG. 12 and described above.

As shown in FIG. 13, the exterior sheathing 1074 has an interior surface1075 and the construction material 1077 has an exterior surface 1078.

The insulative batt 1082 includes an interior surface 1084, positionedto be adjacent the exterior side 1078 of the construction material 1077,and an exterior surface 1085, positioned to be adjacent the interiorsurface 1075 of the exterior sheathing 1074.

In this embodiment, the exterior surface 1085 of the insulative batt1082 includes a facing material 1092. The facing material 1092 isconfigured to prevent a foam composition 1090 from penetrating thefibers of the insulative batt 1082 as the foam composition 1090 forms aseal between the facing material 1092 of the insulative batt 1082 andthe exterior panel 1074. In the illustrated embodiment, the facingmaterial 1092 is made from a polymeric material such as the non-limitingexample of polyfilm and has a thickness in a range of from about 2.0mils to about 10.0 mils. In other embodiments, the facing material 1092can be made from other materials, such as for example, spunbonded olefinor other synthetic material made of high-density polyethylene fibers andcan have a thickness less than about 2.0 mils or more than about 10.0mils.

Referring again to FIG. 13, the facing material 1092 has been fused witha first component 1087 of a two part foaming composition.

In operation, a second component of the foaming composition is pipedthrough the body of the insulative batt 1082, to the exterior surface1085 of the insulative batt 1082, such as to come into contact with, andreact with the first component 1087, thereby forming a layer of foamcomposition 1090 as described above for FIG. 12. The layer of foamcomposition 1090 extends from the exterior surface of the facingmaterial 1092 to the interior surface 1075 of the exterior sheathing,wherein the foam composition forms an intimate seal with the exteriorsheathing 1074.

Similar to the embodiment illustrated in FIG. 12, it should beappreciated that in other embodiments, a pre-mixed foam composition canbe used to form the foam composition 1090.

Another sealing embodiment utilizing a foam composition with aninsulative batt is illustrated in FIG. 14 generally at 1115. Generally,this embodiment involves the use of an air space formed between a layerof foam composition on the insulative batt and the exterior sheathing.The air space acts as an insulative layer.

Referring again to FIG. 14, a portion of a building sidewall 1172 isillustrated. The sidewall 1172 includes various structural framingmembers (not shown), an exterior sheathing 1174 attached to the variousstructural framing members, construction material 1177, insulationcavity 1180 and an insulative batt 1182 positioned within the insulationcavity 1180. In the illustrated embodiment, the various structuralframing members, exterior sheathing 1174, construction material 1177,insulation cavity 1180 and insulative batt 1182 are the same as, orsimilar to, the various structural framing members, exterior sheathing974, construction material 977, insulation cavity 980 and insulativebatt 982 illustrated in FIG. 12 and described above. In otherembodiments, the various structural framing members, exterior sheathing1174, construction material 1177, insulation cavity 1180 and insulativebatt 1182 can be different from the various structural framing members,exterior sheathing 974, construction material 977, insulation cavity 980and insulative batt 982 illustrated in FIG. 12 and described above.

As shown in FIG. 14, the exterior sheathing 1174 has an interior surface1175 and the construction material 1177 has an exterior surface 1178.

The insulative batt 1182 includes an interior surface 1184, positionedto be adjacent the exterior side 1178 of the construction material 1177,and an exterior surface 1185, positioned to be a distance D20 from theinterior surface 1175 of the exterior sheathing 1174. In the illustratedembodiment, the distance D20 is in a range of from about 0.3 inches toabout 1.0 inches. In other embodiments, the distance D20 can be lessthan about 0.3 inches or more than about 1.0 inches.

In this embodiment, the exterior surface 1185 of the insulative batt1182 has been fused with a first component 1187 of a two part foamingcomposition.

In operation, a second component of the foaming composition is pipedthrough the body of the insulative batt 1182, to the exterior surface1185 of the insulative batt 1182, such as to come into contact with, andreact with the first component 1187, thereby forming a layer of foamcomposition 1190 as described above for FIG. 12. The layer of foamcomposition 1190 extends from the exterior surface 1185 of theinsulative batt 1182 toward the exterior sheathing 1174 a distance D30.In the illustrated embodiment, the distance D30 is in a range of fromabout 0.1 inches to about 0.3 inches. In other embodiments, the distanceD30 can be less than about 0.1 inches or more than about 0.3 inches.

As shown in FIG. 14, an air gap 1194 is formed between the layer of foamcomposition 1190 and the interior surface 1175 of the exterior sheathing1174. The air gap 1194 is configured to add to the insulative value ofthe insulative seal 1115. A thickness of the air gap 1194 can bedetermined from the difference between the distance D20 and the distanceD30. In the illustrated embodiment, the thickness of the air gap 1194 isin a range of from about 0.2 inches to about 0.8 inches. Alternatively,the thickness of the air gap 1194 can be less than about 0.2 inches ormore than about 0.8 inches.

Similar to the embodiment illustrated in FIG. 12, it should beappreciated that in other embodiments, a pre-mixed foam composition canbe used to form the foam composition 1190.

The invention of this application has been described above bothgenerically and with regard to specific embodiments, although a widevariety of alternatives known to those of skill in the art can beselected within the generic disclosure. The invention is not otherwiselimited, except for the recitation of the claims set forth below.

What is claimed is:
 1. A system for sealing or insulating a largevolume, the system comprising: an envelope having walls defining aninterior, the interior configured to receive a foaming composition, theenvelope initially configured in a retracted configuration; and afoaming composition configured for insertion into the interior of theenvelope, the foaming composition comprising ceramic foam; wherein theenvelope is configured such that the foaming composition expands theenvelope such as to fill a large gap.
 2. The system of claim 1, whereinthe envelope has the shape of a roll in the retracted configuration. 3.The system of claim 2, wherein the envelope is configured such that theforce of gravity also acts to unroll the envelope.
 4. The system ofclaim 1, wherein the envelope includes a series of leak pores configuredto allow the foaming composition to escape the interior of the envelopeto assist in sealing the large volume.
 5. The system of claim 1, whereinthe foaming composition is configured to dissolve the envelope.
 6. Asystem for sealing or insulating a pipe or ductwork, the systemcomprising: an envelope having an inner skin and an outer skinconfigured for wrapping around the pipe or ductwork, the inner skin andthe outer skin defining an interior, the interior configured to receivea foaming composition, the envelope initially configured in a non-rigidstructure; and a foaming composition configured for insertion into theinterior of the envelope, the foaming composition comprising ceramicfoam; wherein the envelope is configured such that the foamingcomposition expands the envelope such as to form a insulation structurearound the pipe or ductwork.
 7. The system of claim 6, wherein theenvelope extends substantially the lengths of the pipe or ductwork. 8.The system of claim 6, wherein the inner skin and the outer skin areconnected to each other by a plurality of members.
 9. The system ofclaim 6, wherein the inner skin and the outer skin of the insulationstructure are concentric about the pipe.
 10. The system of claim 6,wherein the inner skin includes a series of leak pores configured toallow the foaming composition to escape the interior of the envelope toassist in sealing the pipe or ductwork.
 11. The system of claim 6,wherein the foaming composition is configured to dissolve the envelope.12. A system for sealing or insulating an insulation cavity formedbetween internal and external materials, the system comprising: aninsulative batt positioned between the internal and external materials,the insulative batt having a first component of a foaming compositionfused to a surface of the insulative batt adjacent the externalmaterial; and a fitment port configured to extend through the insulativebatt and further configured to facilitate injection of a secondcomponent of the foaming composition; wherein the first component of thefoaming composition is configured to react with the second component ofthe foaming composition such as to form a layer of foam composition thatseals with the exterior material.
 13. The system of claim 12, whereinthe layer of foam composition is in a range of from about 0.1 inches toabout 0.3 inches.
 14. The system of claim 12, wherein the firstcomponent of the foaming composition is fused to a facing material. 15.The system of claim 12, wherein an air gap is formed between the layerof foam composition and the external materials.
 16. The system of claim15, wherein the air gap has a thickness in a range of from about 0.2inches to about 0.8 inches.
 17. A system for sealing or insulating aninsulation cavity formed between internal and external materials, thesystem comprising: an insulative batt positioned between the internaland external materials, the insulative batt having a surface positionedadjacent the external material; and a fitment port configured to extendthrough the insulative batt and further configured to facilitateinjection of a foaming composition; wherein the foaming composition isconfigured to form a layer of foam composition that seals the insulativebatt with the exterior material.
 18. The system of claim 17, wherein thelayer of foam composition is in a range of from about 0.1 inches toabout 0.3 inches.
 19. The system of claim 17, wherein the insulativebatt includes a facing material, and wherein the foaming composition isconfigured to form a layer of foam composition that seals the insulativebatt with the exterior material.
 20. The system of claim 17, wherein anair gap is formed between the layer of foam composition and the externalmaterial.
 21. The system of claim 20, wherein the air gap has athickness in a range of from about 0.2 inches to about 0.8 inches.
 22. Asystem for sealing or insulating a large volume, the system comprising:an envelope having walls defining an interior, the interior configuredto receive a foaming composition, the envelope initially configured in aretracted configuration; and a foaming composition configured forinsertion into the interior of the envelope, wherein the foamingcomposition is configured to dissolve the envelope; wherein the envelopeis configured such that the foaming composition expands the envelopesuch as to fill a large gap.
 23. The system of claim 22, wherein theenvelope has the shape of a roll in the retracted configuration.
 24. Thesystem of claim 23, wherein the envelope is configured such that theforce of gravity also acts to unroll the envelope.
 25. The system ofclaim 22, wherein the envelope includes a series of leak poresconfigured to allow the foaming composition to escape the interior ofthe envelope to assist in sealing the large volume.
 26. A system forsealing or insulating a pipe or ductwork, the system comprising: anenvelope having an inner skin and an outer skin configured for wrappingaround the pipe or ductwork, the inner skin and the outer skin definingan interior, the interior configured to receive a foaming composition,the envelope initially configured in a non-rigid structure; and afoaming composition configured for insertion into the interior of theenvelope, wherein the foaming composition is configured to dissolve theenvelope; wherein the envelope is configured such that the foamingcomposition expands the envelope such as to form a insulation structurearound the pipe or ductwork.
 27. The system of claim 26, wherein theenvelope extends substantially the lengths of the pipe or ductwork. 28.The system of claim 26, wherein the inner skin and the outer skin areconnected to each other by a plurality of members.
 29. The system ofclaim 26, wherein the inner skin and the outer skin of the insulationstructure are concentric about the pipe.
 30. The invention of claim 26,wherein the inner skin includes a series of leak pores configured toallow the foaming composition to escape the interior of the envelope toassist in sealing the pipe or ductwork.